Method of ultrasonically treating a substance

ABSTRACT

In a method of ultrasonically treating a substance disposed within a container an ultrasonic horn is positioned within the container with at least a portion of the horn submerged in the substance. The horn is ultrasonically excited to thereby ultrasonically energize the substance. An agitating member is rotated within the substance while the ultrasonic horn is excited to agitate the substance as the substance is ultrasonically energized.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.12/438,317, filed on Oct. 28, 2009, which is a U.S. National Stagepatent application of International Application Serial NumberPCT/IB2007/053623, filed on Sep. 7, 2007, which is acontinuation-in-part application of U.S. patent application Ser. No.11/530,311, filed on Sep. 8, 2006, now issued as U.S. Pat. No.7,703,698. Each of these applications is hereby incorporated byreference in their entirety.

FIELD OF INVENTION

This invention relates generally to systems for ultrasonically treatinga substance, and more particularly to an ultrasonic treatment system forultrasonically agitating a substance.

BACKGROUND

The agitation of liquid solutions finds numerous applications forenhancing the treatment of a liquid such as single component liquid,liquid-liquid mixing, liquid-gas mixing and liquid-particulate materialmixing. For example, in formulating inks, paints and other viscousmaterials two or more components (at least one being a liquid) are mixedtogether to form the applicable solution. Other examples include thesimultaneous introduction of various liquids and gases into the chamberto promote certain reactions. This would include the flow of water intothe chamber with the introduction of gases such as air and/or oxygenand/or ozone only to mention a few. Also this chamber can be used toinduce a variety of chemical reactions such as the decomposition ofhydrogen peroxide, emulsion polymerization reactions and the creation ofemulsions for emulsion polymerization mechanisms.

In other applications, this system can be used for the deagglomerationof particles in a liquid stream. This would include the deagglomerationof nano-particles such as pigments used in the formulation of inks. Plusthe simultaneous formulation of an ink using these nano-pigmentparticles. This system can also have the simultaneous exposure toUltraViolet (UV) light to promote certain reactions of fluids orfluid/gas or fluid/gas/solids systems in the ultrasonic chamber. Anotherapplication could be in the medical field where this mixing system isused in the preparation of pharmaceutical formulations that are composedof powders/liquids and liquids for dispensing for use.

In particular, such agitation treatments lend themselves to continuoustype flow treatment systems in which the liquid is treated whilecontinuously moving through the system, usually through a column orelongate chamber. By agitating the liquid, the desired reaction (e.g.,mixing or other result) may be expedited and thus capable of beingachieved in a continuous flow operation.

Agitation of a liquid may be referred to as static agitation, in whichagitation is caused by the particular flow parameters (e.g., flow rate,pressure, etc.) of the one or more liquid components through a column.Static agitation may also occur by directing a flow of liquid paststationary agitating members, such as a helical vane-type constructionor other structures disposed in the flow column or chamber that disruptand thus turbulate the flow of the liquid to be treated. Dynamicagitation is brought about by moving, e.g., rotating, oscillating,vibrating, etc. one or more agitating members (e.g., vanes, fan blades,etc.) within the treatment chamber through which the liquid flows.

One particularly useful type of dynamic agitation of the liquid resultsfrom ultrasonic cavitation, a more rigorous agitation, in the liquid.Ultrasonic cavitation refers to the formation, growth and implosivecollapse of bubbles in liquid due ultrasonic energization thereof. Suchcavitation results from pre-existing weak points in the liquid, such asgas-filled crevices in suspended particulate matter or transientmicrobubbles from prior cavitation events. As ultrasound passes througha liquid, the expansion cycles exert negative pressure on the liquid,pulling the molecules away from one another. Where the ultrasonic energyis sufficiently intense, the expansion cycle creates cavities in theliquid when the negative pressure exceeds the local tensile strength ofthe liquid, which varies according to the type and purity of liquid.

Small gas bubbles formed by the initial cavities grow upon furtherabsorption of the ultrasonic energy. Under the proper conditions, thesebubbles undergo a violent collapse, generating very high pressures andtemperatures. In some fields, such as what is known as sonochemistry,chemical reactions take advantage of these high pressures andtemperatures brought on by cavitation. However, the growth and violentcollapse of the bubbles themselves provides a desirably rigorousagitation of the liquid. Cavitation that occurs at the interface betweenthe ultrasonically energized liquid and a solid surface is ratherasymmetric and generates high speed jets of liquid, further agitatingthe liquid. This type of cavitation is particularly useful, for example,in facilitating a more complete mixing together of two or morecomponents of a liquid solution.

Another example of an application wherein substances are agitatedincludes the mixing of solutions that have separated or partiallyseparated into different components making up the liquid solution. Theseparation can be two or more liquids separating into different phaseswherein the more dense liquid(s) will settle below the less denseliquid(s). The separation can also be were a particulate materialsettles below the liquid. It is common that the separated/partiallyseparated liquid solution has to be remixed before it can be used.

In yet another example, some substances set up over time. That is, theysolidify, partially solidify, or turn gelatinous. Often these substanceshave to be made ready to flow (e.g., less viscous) before they can beused. Typically, these substances are warmed using an external heaterwherein a heating source is placed on the outside of the containerholding the substance. The heat source is then activated to heat thecontainer and thereby the substance. The substance, once heated, isrendered more ready to flow. However, this type of heating process canbe relatively slow and inefficient.

SUMMARY

In one aspect, a method of ultrasonically treating a substance disposedwithin a container generally comprises positioning an ultrasonic hornwithin the container with at least a portion of the horn submerged inthe substance. The horn is ultrasonically excited to therebyultrasonically energize the substance. An agitating member is rotatedwithin the substance while the ultrasonic horn is excited to agitate thesubstance as the substance is ultrasonically energized.

In another aspect, a method of ultrasonically treating a substancedisposed within a container generally comprises positioning anultrasonic horn within the container with at least a portion of the hornsubmerged in the substance. An agitating member is positioned on theportion of the ultrasonic horn that is submerged in the substance. Thehorn is ultrasonically excited to thereby ultrasonically energize thesubstance. The agitating member is rotated within the substance whilethe ultrasonic horn is excited to agitate the substance as the substanceis ultrasonically energized.

In yet another aspect, a method of ultrasonically treating a substancedisposed within a container generally comprises positioning anultrasonic horn within the container with at least a portion of the hornsubmerged in the substance. The horn is ultrasonically excited tothereby ultrasonically energize the substance. A plurality of agitatingmembers is rotated within the substance while the ultrasonic horn isexcited to agitate the substance as the substance is ultrasonicallyenergized. The plurality of agitating members is disposed on the hornand in longitudinal spaced relationship with each other.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic of a mixing system according to one embodiment ofa system for ultrasonically treating a liquid illustrated in the form ofan ink solution mixing system and incorporating an ultrasonic treatmentchamber for ultrasonically treating a liquid;

FIG. 2 is a side elevation of an ultrasonic treatment chamber forultrasonically treating a liquid;

FIG. 3 is a longitudinal (e.g., vertical) cross-section of theultrasonic treatment chamber of FIG. 2;

FIG. 3A is an enlarged, fragmented view of a portion of thecross-section of FIG. 3;

FIG. 3B is a top plan view of a collar that forms part of the housing ofthe ultrasonic treatment chamber of FIG. 2;

FIG. 4 is an exploded perspective of a horn assembly and a baffleassembly of the ultrasonic treatment chamber of FIG. 2;

FIG. 5 is a front perspective of an alternative embodiment of a hornassembly;

FIG. 6 is a fragmented and enlarged longitudinal cross-section similarto that of FIG. 3A but illustrating an alternative embodiment of abaffle assembly;

FIG. 7 is a front perspective of another alternative embodiment of abaffle assembly;

FIG. 8 is an exploded view thereof;

FIG. 9 is a longitudinal (e.g., vertical) cross-section thereof;

FIG. 10 is a side elevation of an ultrasonic treatment device with partsthereof being broken away to show internal components, the ultrasonictreatment device being supported by a support structure; and

FIG. 11 is a side elevation of an ultrasonic treatment device havinganother embodiment.

Corresponding reference characters indicate corresponding partsthroughout the drawings.

DETAILED DESCRIPTION OF THE DRAWINGS

With particular reference now to FIG. 1, in one embodiment a system forultrasonically treating a liquid generally comprises an ultrasonictreatment chamber, generally indicated at 21, that is operable toultrasonically treat a liquid. The term “liquid” as used herein isintended to refer to a single component liquid, a solution comprised oftwo or more components in which at least one of the components is aliquid such as a liquid-liquid mixture, a liquid-gas mixture or a liquidin which particulate matter is entrained, or other viscous fluids.

The ultrasonic treatment chamber 21 is illustrated schematically in FIG.1 and further described herein with reference to use of the treatmentchamber in a mixing system, generally indicated at 23, used to form aliquid solution by mixing together two or more components in which atleast one of the components is a liquid by applying ultrasonic energy tothe solution within the chamber, and more particularly to such a mixingsystem for forming a liquid ink solution from two or more inkcomponents. It is understood, however, that the ultrasonic treatmentchamber 21 illustrated and described herein may be used with mixingsystems for forming liquid solutions other than liquid ink solutions. Itis also understood that the ultrasonic treatment chamber 21 may be usedin liquid ultrasonic treatment systems other than for mixing but whereultrasonic agitation of the liquid at least in part comprises thedesired treatment of the liquid.

In particular, the ultrasonic treatment chamber 21 is suitable for usein liquid treatment systems in which ultrasonic agitation of the liquidis desired in an in-line, e.g., continuous flow process in which fluidflows continuously through the chamber. Examples of other contemplateduses of the ultrasonic treatment chamber include, without limitation,mixing solutions, paints and other viscous materials (e.g., other thanink solutions); food processing and treatment; degassing solutions(e.g., pulling dissolved gasses from liquid solutions such as oxygen,nitrogen, ammonia, etc.); and enhancing chemical reactions, for example,as is common in sonochemistry where excitation is imparted to a chemicalreaction to expedite the reaction. It is contemplated, though, that thetreatment chamber 21 may be used in a liquid treatment system in whichliquid is treated in accordance with a batch process instead of acontinuous flow process and remain with the scope of this invention.

Additional examples of contemplated mixing uses for the ultrasonictreatment chamber 21 include, without limitation, mixing resins andcuring agents for the plastic industry; mixing pulp slurries withchemical additives such as bleaching agents, wet strength agents,starches, dyes, enzymes, fillers, anti-slime agents, silicone additives,etc.; mixing compounds used in the paper and tissue industries, such asclay slurries for coatings, polymeric additives such as wet strengthresins, starch suspensions, silicone compounds, lotions, fillersuspensions, etc.; mixing resins and coloring agents, fillers, and othercompounds; mixing immiscible phases to prepare emulsions, such as foodemulsions (e.g., for sun block products, hand lotions, lipstickcompounds, etc.), cosmetics, cleaning agents (including nanoemulsions ofoil and water), pharmaceutical compounds, etc; and mixing coloringagents and other compounds to form cosmetics such as hair dyes.

Other contemplated uses of the ultrasonic treatment chamber 21 include,without limitation, degassing a mixture to simplify subsequent treatmentand reduce void formation; deinking recycled papermaking fibers, inwhich ultrasonic energy may assist in removal of inks (particularly inthe presence of enzymes, detergents, or other chemicals); hydrogenatingoils, cheese, or other food stuffs, in which gas and slurries or liquidsmust be mixed; homogenizing milk and other compounds; incorporating intobioreactors and fermentation units, in which delicate cells must bemixed with nutrients and other compounds without intense mechanicalshear that might damage cells; treating wastewater and/or manure, inwhich a variety of additives and air bubbles may need to be mixed with aslurry; manufacturing petrochemicals such as lubricant mixtures,gasoline blends, wax mixtures, etc., and compounds derived frompetrochemicals; processing dough (e.g., mixing combinations of agents tobe added to flour or processing the dough itself, which may result inimproved breakdown of gluten, etc.). The ultrasonic treatment chamber 21may also be used in chemical reactors involving single or multiplephases, including slurries.

In other contemplated uses, the ultrasonic treatment chamber 21 may beused to remove entrapped gas bubbles from coating solutions that areused in gravure coating, meyer rod coating or any other coatingapplications where it is desirable to remove air bubbles from asolution.

In the illustrated embodiment of FIG. 1, the ultrasonic treatmentchamber 21 is generally elongate and has a general inlet end 25 (a lowerend in the orientation of the illustrated embodiment) and a generaloutlet end 27 (an upper end in the orientation of the illustratedembodiment). The system 23 is configured such that fluid enters thetreatment chamber 21 generally at the inlet end 25 thereof, flowsgenerally longitudinally within the chamber (e.g., upward in theorientation of illustrated embodiment) and exits the chamber generallyat the outlet end of the chamber.

The terms “upper” and “lower” are used herein in accordance with thevertical orientation of the ultrasonic treatment chamber 21 illustratedin the various drawings and are not intended to describe a necessaryorientation of the chamber in use. That is, while the chamber 21 is mostsuitably oriented vertically, with the outlet end 27 of the chamberabove the inlet end 25 as illustrated in the various drawings, it isunderstood that the chamber may be oriented with the inlet end above theoutlet end, or it may be oriented other than in a vertical orientationand remain within the scope of this invention.

The terms axial and longitudinal refer directionally herein to thelengthwise direction of the chamber 21 (e.g., end-to-end such as thevertical direction in the illustrated embodiments). The termstransverse, lateral and radial refer herein to a direction normal to theaxial (e.g., longitudinal) direction. The terms inner and outer are alsoused in reference to a direction transverse to the axial direction ofthe ultrasonic treatment chamber 21, with the term inner referring to adirection toward the interior of the chamber (e.g., toward thelongitudinal axis of the chamber) and the term outer referring to adirection toward the exterior of the chamber (e.g., away from thelongitudinal axis of the chamber).

The inlet end 25 of the ultrasonic treatment chamber 21 is in fluidcommunication with a suitable delivery system, generally indicated at29, that is operable to direct one or more liquid components to, andmore suitably through, the chamber 21. For example, in the illustratedliquid ink solution mixing system 23 of FIG. 1 the delivery system 29comprises a plurality of pumps 31 (such as one pump for each inkcomponent to be mixed together) operable to pump the respectivecomponents from a corresponding source (illustrated schematically inFIG. 1 as reference number 32 thereof) to the inlet end 25 of thechamber 21 via suitable conduits (illustrated schematically in FIG. 1 asreference number 33). As an example, four such pumps 31, componentsources and corresponding conduits 33 are shown in FIG. 1 for deliveringa combination of ink components including, for example components usedfor forming a pigmented ink solution such as, without limitation, apigment dispersion, water, glycerin, a binder, a surfactant and/or abiocide, or components for forming a reactive ink solution such as,without limitation, a dye or lake, water, glycerin, a surfactant, abiocide and a binder, or components for forming other liquid inksolutions.

It is understood that the delivery system 29 may be configured todeliver less than four (including one), or more than four components tothe treatment chamber 21 without departing from the scope of thisinvention. It is also contemplated that delivery systems other than thatillustrated in FIG. 1 and described herein may be used to deliver one ormore components to the inlet end 25 of the ultrasonic treatment chamber21 without departing from the scope of this invention.

The ink mixing system 23 of the illustrated embodiment also comprises apost-processing system, generally indicated at 35, in fluidcommunication with the outlet end 27 of the ultrasonic treatment chamber21 for processing liquid solution (e.g., the ink solution) after theliquid solution exits the chamber. The illustrated mixing system 23comprises one or more pressure gauges 37 (two are illustrated in FIG. 1)to monitor the liquid pressure in the mixing system. One or more filterunits 39 a, 39 b may also be disposed along the flow path of the liquidsolution downstream of the treatment chamber 21 to filter outparticulate material, such as dirt, debris or other contaminates thatmay be present in the liquid solution (e.g., from initially beingpresent in one or more of the components delivered to the chamber) fromthe liquid solution. For example, in the illustrated embodiment a firstfilter unit 39 a is constructed to filter out particles sized greaterthan about 0.5 microns and a second filter unit 39 b downstream from thefirst filter unit is constructed to further filter out particles sizedgreater than about 0.2 microns. It is understood, however, that onlyone, or more than two filter units 39 a, 39 b may be used, or that thefilter units may be omitted altogether, without departing from the scopeof this invention.

Still referring to FIG. 1, the post-processing system 35 may furthercomprise a degassing and bubble removal unit 41 that is operable toremove gas bubbles from the liquid solution (e.g., the ink solution)after the ultrasonic treatment in the treatment chamber 21. In oneparticularly suitable embodiment the degassing and bubble removal unit41 comprises a conventional membrane contactor. The construction andoperation of membrane contactors is well known to those skilled in theart and is therefore not described in further detail herein. One exampleof a suitable membrane contactor is that available from Membrana ofCharlotte, N.C., U.S.A. under the trade name SuperPhobic. One or moresensor units 43 may also be provided to monitor various characteristicsof the liquid solution (e.g., the ink solution) such as, withoutlimitation, pH, conductivity, viscosity, temperature, color, surfacetension and other characteristics.

Following post-processing, the liquid treated by the ultrasonictreatment chamber 21 may be directed to a storage container or operatingdevice (either of which is indicated schematically by the singlereference number 45) having any of a number of applications. Forexample, the liquid ink solution mixing system 23 of FIG. 1 may deliverink solution directly into an ink-jet head for continuous delivery ofink solution onto substrates, or pumped directly into a coater, such asa slot die, gravure, silk screen, meyer rod, roller, spray or othersuitable coater for use in coating substrates with ink solution.Examples of other applications include, without limitation, the deliveryof the treated liquid to a spray nozzle for atomization, or the deliveryof the treated liquid to an injection molding or a reactive injectionmolding. Any system (not shown) used to deliver the treated liquid to anapplicator may be disposed downstream of the post-processing system(such as post-processing system 35), or the post-processing system maybe omitted and a system (not shown) may communicate directly with theoutlet port 65 of the chamber 21 to deliver the treated liquid to asubsequent applicator.

With reference now to FIG. 2, the ultrasonic treatment chamber 21 of theliquid treatment system 23 comprises a housing 51 defining an interiorspace 53 of the chamber through which liquid delivered to the chamberflows from the inlet end 25 to the outlet end 27 thereof. The housing 51suitably comprises an elongate tube 55 generally defining, at least inpart, a sidewall 57 of the chamber 21. The tube 55 may have one or moreinlet ports (one such inlet port being illustrated in FIG. 2 andindicated at 59) formed therein through which one or more components tobe treated within the chamber 21 are delivered to the interior space 53thereof. In the illustrated embodiment, the housing 51 further comprisesan inlet collar 61 that is connected to and mounted on one end of thetube 55 to further define (along with the inlet port 59) the inlet end25 of the chamber 21.

The housing 51 also comprises a closure 63 connected to andsubstantially closing the longitudinally opposite end of the sidewall57, and having at least one outlet port 65 therein to generally definethe outlet end 27 of the treatment chamber 21. The sidewall 57 (e.g.,defined by the elongate tube 55) of the chamber 21 has an inner surface67 that together with the collar 61 and the closure 63 define theinterior space 53 of the chamber. In the illustrated embodiment, thetube 55 is generally cylindrical so that the chamber sidewall 57 isgenerally annular in cross-section. However, it is contemplated that thecross-section of the chamber sidewall 57 may be other than annular, suchas polygonal or another suitable shape, and remain within the scope ofthis invention. The chamber sidewall 57 of the illustrated chamber 21 issuitably constructed of a transparent material, although it isunderstood that any suitable material may be used as long as thematerial is compatible with the liquid components being treated in thechamber, the pressure at which the chamber is intended to operate, andother environmental conditions within the chamber such as temperature.

With particular reference to FIG. 3B, the inlet collar 61 at the inletend 25 of the chamber 21 is generally annular and has at least one, andmore suitably a plurality of inlet ports 69 a, 69 b formed therein forreceiving liquid solution components into the interior space 53 of thechamber 21. At least one inlet port 69 a is oriented generallytangentially relative to the annular collar 61 so that liquid flows intothe interior space 53 of the chamber 21 generally tangentially theretoto impart a swirling action to liquid as it enters the chamber. Moresuitably, in the illustrated embodiment a pair of inlet ports 69 a, 69 bare arranged in parallel alignment with each and extend generallytangentially relative to the annular collar 61, with one port 69 a beingdesignated herein as the outer inlet port and the other port 69 b beingdesignated the inner inlet port.

This dual tangential inlet port 69 a, 69 b arrangement is particularlyuseful for initiating mixing of two or more components together beforethe liquid solution is further subjected to ultrasonic treatment withinthe chamber 21. In a particularly suitable use of this arrangement,where the liquid to be treated in the chamber 21 comprises two or moreliquids, the liquid having the lowest viscosity is directed to flow intothe chamber via the outer inlet port 69 a while the liquid having thehighest viscosity is directed to flow into the chamber via the innerinlet port 69 b. The flow of the lower viscosity ingredient through theouter inlet port 69 a has a tendency to draw the higher viscosityingredient into the interior space 53 of the chamber 21 to speed therate at which the higher viscosity ingredient is introduced into thechamber.

This action, combined with the swirling action resulting from thetangential direction in which the liquid components are directed intothe chamber 21, facilitate an initial mixing of these two componentsbefore the liquid solution flows further through the chamber forultrasonic treatment. If additional components are to be added to themixture, such components may be delivered into the interior space 53 ofthe chamber 21 via the inlet port 59 formed in the chamber sidewall 57.In the illustrated embodiment, the collar 61 also has an additionaltangential set of inlet ports and a pair of generally verticallyoriented inlet ports 71. It is understood, however, that none of theports 69 a, 69 b need to be oriented tangentially relative to the collar61 to remain within the scope of this invention. It is also contemplatedthat the collar 61 may be omitted altogether such that all components tobe mixed together are delivered to the inlet port 59 formed in thechamber sidewall 57.

An ultrasonic waveguide assembly, generally indicated at 101, extendslongitudinally at least in part within the interior space 53 of thechamber 21 to ultrasonically energize liquid (and any other componentsof the liquid solution) flowing through the interior space 53 of thechamber. In particular, the ultrasonic waveguide assembly 101 of theillustrated embodiment extends longitudinally from the lower or inletend 25 of the chamber 21 up into the interior space 53 thereof to aterminal end 103 of the waveguide assembly disposed intermediate theuppermost inlet port (e.g., inlet port 59 where it is present, orotherwise inlet ports 69 a, 69 b). More suitably, the waveguide assembly101 is mounted, either directly or indirectly, to the chamber housing 51as will be described later herein.

The ultrasonic waveguide assembly 101 suitably comprises an elongatehorn assembly, generally indicated at 105, disposed entirely with theinterior space 53 of the housing 51 intermediate the uppermost inletport and the outlet port for complete submersion within the liquid beingtreated within the chamber 21, and more suitably it is aligned coaxiallywith the chamber sidewall 57. The horn assembly 105 has an outer surface107 that together with the inner surface 67 of the sidewall 57 defines aflow path within the interior space 53 of the chamber 21 along whichliquid and other components flow past the horn assembly within thechamber (this portion of the flow path being broadly referred to hereinas the ultrasonic treatment zone). The horn assembly 105 has an upperend 109 defining a terminal end of the horn assembly (and therefore theterminal end 103 of the waveguide assembly) and a longitudinallyopposite lower end 111. The waveguide assembly 101 of the illustratedembodiment also comprises a booster 113 coaxially aligned with andconnected at an upper end thereof to the lower end 111 of the hornassembly 105. It is understood, however, that the waveguide assembly 101may comprise only the horn assembly 105 and remain within the scope ofthis invention. It is also contemplated that the booster 113 may bedisposed entirely exterior of the chamber housing 51, with the hornassembly 105 mounted on the chamber housing 51 without departing fromthe scope of this invention.

The ultrasonic waveguide assembly 101, and more particularly the booster113 in the illustrated embodiment of FIG. 3, is suitably mounted on thechamber housing 51, e.g., on the tube 55 defining the chamber sidewall57, at the upper end thereof by a mounting member 115 that is configuredto vibrationally isolate the waveguide assembly (which vibratesultrasonically during operation thereof) from the ultrasonic treatmentchamber housing. That is, the mounting member 115 inhibits the transferof longitudinal and transverse mechanical vibration of the waveguideassembly 101 to the chamber housing 51 while maintaining the desiredtransverse position of the waveguide assembly (and in particular thehorn assembly 105) within the interior space 53 of the chamber housingand allowing both longitudinal and transverse displacement of the hornassembly within the chamber housing. In the illustrated embodiment, themounting member 115 also at least in part (e.g., along with the booster113) closes the inlet end 25 of the chamber 21.

As one example, the mounting member 115 of the illustrated embodimentgenerally comprises an annular outer segment 117 extending transverse tothe waveguide assembly 101 in transversely spaced relationshiptherewith, and a flange member 119 interconnecting the outer segment tothe waveguide assembly. While the flange member 119 and transverse outersegment 117 of the mounting member 115 extend continuously about thecircumference of the waveguide assembly 101, it is understood that oneor more of these elements may be discontinuous about the waveguideassembly such as in the manner of wheel spokes, without departing fromthe scope of this invention. The outer segment 117 of the mountingmember 115 is particularly configured to seat down against a shoulder121 formed by the inlet collar 61.

As seen best in FIG. 6, the internal cross-sectional dimension (e.g.,internal diameter) of the collar 61 is stepped outward as the collarextends longitudinally downward away from the chamber sidewall 57 toaccommodate the flange member 119. In one particularly suitableembodiment, the collar 61 is sufficiently sized to be transverselyspaced from the flange member 119 to define a generally annular gap 123therebetween in which liquid delivered to the chamber 21 via the inletports 69 a, 69 b of the collar enters the interior space 53 of thechamber. This annular gap 123 further facilitates the swirling action ofthe liquid upon entry into the chamber 21 via the collar inlet ports 69a, 69 b.

The mounting member 115 is suitably sized in transverse cross-section sothat at least an outer edge margin of the outer segment 117, and moresuitably a substantial transverse portion of the outer segment is seatedon the shoulder 121 formed on the collar 61. A suitable fastening system(not shown), such as a plurality of bolts and corresponding nuts (notshown), secures the outer segment 117 of the mounting member 115 to theshoulder 121 formed by the collar 61 to thereby connect the booster 113(and more broadly the waveguide assembly 101) to the chamber housing 51.

The flange member 119 may suitably be constructed relatively thinnerthan the outer segment 117 of the mounting member 115 to facilitateflexing and/or bending of the flange member 119 in response toultrasonic vibration of the waveguide assembly 101. As an example, inone embodiment the thickness of the flange member 119 may be in therange of about 0.2 mm to about 5 mm, and more suitably about 2.5 mm. Theflange member 119 of the illustrated mounting member 115 suitably has aninner transverse component 125 connected to the waveguide assembly 101and extending generally transversely outward therefrom but inward of theouter segment 117 of the mounting member, and an axial, or longitudinalcomponent 127 interconnecting the transverse inner component with theouter segment of the mounting member and together with the transverseinner component generally forming a generally L-shaped cross-section ofthe flange member 119. It is contemplated, however, that the flangemember 119 may instead have a generally U-shaped cross-section or othersuitable cross-sectional shape such as an H-shape, an I-shape, aninverted U-shape and the like and remain within the scope of thisinvention. Additional examples of suitable mounting member 115configurations are illustrated and described in U.S. Pat. No. 6,676,003,the entire disclosure of which is incorporated herein by reference tothe extent it is consistent herewith.

The longitudinal component 127 of the illustrated flange member 119 issuitably cantilevered to the transverse outer segment 117 and to thetransverse inner component 125 of the flange member, while the innercomponent of the flange member is cantilevered to the waveguide assembly101. Accordingly, the flange member 119 is capable of dynamicallybending and/or flexing relative to the outer segment 117 of the mountingmember 115 in response to vibratory displacement of the waveguideassembly 101 to thereby isolate the chamber housing 51 from transverseand longitudinal displacement of the waveguide assembly.

While in the illustrated embodiment the transverse outer segment 117 ofthe mounting member 115 and the transverse inner component 125 of theflange member 119 are disposed generally at longitudinally offsetlocations relative to each other, it is understood that they may bedisposed at generally the same location (e.g., where the flange memberis generally U-shaped in cross-section) or at locations other than thoseillustrated in FIG. 3) without departing from the scope of thisinvention.

In one particularly suitable embodiment the mounting member 115 is ofsingle piece construction. Even more suitably the mounting member 115may be formed integrally with the booster 113 (and more broadly with thewaveguide assembly 101) as illustrated in FIG. 3. However, it isunderstood that the mounting member 115 may be constructed separate fromthe waveguide assembly 101 and remain within the scope of thisinvention. It is also understood that one or more components of themounting member 115 may be separately constructed and suitably connectedor otherwise assembled together.

In one suitable embodiment the mounting member 115 is furtherconstructed to be generally rigid (e.g., resistant to staticdisplacement under load) so as to hold the waveguide assembly 101 inproper alignment within the interior space 53 of the chamber 21. Forexample, the rigid mounting member 115 in one embodiment may beconstructed of a non-elastomeric material, more suitably metal, and evenmore suitably the same metal from which the booster 113 (and morebroadly the waveguide assembly 101) is constructed. The term rigid isnot, however, intended to mean that the mounting member 115 is incapableof dynamic flexing and/or bending in response to ultrasonic vibration ofthe waveguide assembly 101. In other embodiments, the rigid mountingmember 115 may be constructed of an elastomeric material that issufficiently resistant to static displacement under load but isotherwise capable of dynamic flexing and/or bending in response toultrasonic vibration of the waveguide assembly 101. While the mountingmember 115 illustrated in FIG. 3 is constructed of a metal, and moresuitably constructed of the same material as the booster 113, it iscontemplated that the mounting member may be constructed of othersuitable generally rigid materials without departing from the scope ofthis invention.

A suitable ultrasonic drive system 131 (shown schematically in FIG. 1)including at least an exciter (not shown) and a power source (not shown)is disposed exterior of the chamber 21 and operatively connected to thebooster 113 (and more broadly to the waveguide assembly 101) to energizethe waveguide assembly to mechanically vibrate ultrasonically. Examplesof suitable ultrasonic drive systems 131 include a Model 20A3000 systemavailable from Dukane Ultrasonics of St. Charles, Ill., and a Model2000CS system available from Herrmann Ultrasonics of Schaumberg, Ill.

In one embodiment, the drive system 131 is capable of operating thewaveguide assembly 101 at a frequency in the range of about 15 kHz toabout 100 kHz, more suitably in the range of about 15 kHz to about 60kHz, and even more suitably in the range of about 20 kHz to about 40kHz. Such ultrasonic drive systems 131 are well known to those skilledin the art and need not be further described herein.

With particular reference to FIG. 3, the horn assembly 105 comprises anelongate, generally cylindrical horn 133 having an outer surface 135,and two or more (i.e., a plurality of) agitating members 137 connectedto the horn and extending at least in part transversely outward from theouter surface of the horn in longitudinally spaced relationship witheach other. The horn 133 is suitably sized to have a length equal toabout one-half of the resonating wavelength (otherwise commonly referredto as one-half wavelength) of the horn. In one particular embodiment,the horn 133 is suitably configured to resonate in the ultrasonicfrequency ranges recited previously, and most suitably at 20 kHz. Forexample, the horn 133 may be suitably constructed of a titanium alloy(e.g., Ti6Al4V) and sized to resonate at 20 kHz. The one-half wavelengthhorn 133 operating at such frequencies thus has a length (correspondingto a one-half wavelength) in the range of about 4 inches to about 6inches, more suitably in the range of about 4.5 inches to about 5.5inches, even more suitably in the range of about 5.0 inches to about 5.5inches, and most suitably a length of about 5.25 inches (133.4 mm). Itis understood, however, that the ultrasonic treatment chamber 21 mayinclude a horn assembly 105 in which the horn 133 is sized to have anyincrement of one-half wavelength without departing from the scope ofthis invention.

In the illustrated embodiment, the agitating members 137 comprise aseries of six washer-shaped rings that extend continuously about thecircumference of the horn member 133 in longitudinally spacedrelationship with each other and transversely (e.g., radially in theillustrated embodiment) outward from the outer surface of the horn. Inthis manner the vibrational displacement of each of the agitatingmembers 137 relative to the horn 133 is relatively uniform about thecircumference of the horn. It is understood, however, that the agitatingmembers 137 need not each be continuous about the circumference of thehorn 133. For example, the agitating members 137 may instead be in theform of spokes, blades, fins or other discrete structural members thatextend transversely outward from the outer surface 135 of the horn 133.

To provide a dimensional example, for the horn 133 of the illustratedembodiment of FIG. 3 having a length of about 5.25 inches (133.4 mm),one of the rings 137 is suitably disposed adjacent the terminal end ofthe horn 133 (and hence of the waveguide assembly 101), and moresuitably is longitudinally spaced approximately 0.063 inches (1.6 mm)from the terminal end of the horn member. In other embodiments theuppermost ring 137 may be disposed at the terminal end of the horn andremain within the scope of this invention. The rings 137 are each about0.125 inches (3.2 mm) in thickness and are longitudinally spaced fromeach other (between facing surfaces of the rings) a distance of about0.875 inches (22.2 mm).

It is understood that the number of agitating members 137 (e.g., therings in the illustrated embodiment) may be less than or more than sixwithout departing from the scope of this invention. It is alsounderstood that the longitudinal spacing between the agitating members137 may be other than as illustrated in FIG. 3 and described above(e.g., either closer or spaced further apart). While the rings 137illustrated in FIG. 3 are equally longitudinally spaced from each other,it is alternatively contemplated that where more than two agitatingmembers are present the spacing between longitudinally consecutiveagitating members need not be uniform to remain within the scope of thisinvention.

In particular, the locations of the agitating members 137 are at leastin part a function of the intended vibratory displacement of theagitating members upon vibration of the horn 133. For example, in theillustrated embodiment the horn 133 has a nodal region located generallylongitudinally centrally of the horn (e.g., between the third and fourthrings). As used herein, the “nodal region” of the horn 133 refers to alongitudinal region or segment of the horn member along which little (orno) longitudinal displacement occurs during ultrasonic vibration of thehorn and transverse (e.g., radial in the illustrated embodiment)displacement of the horn is generally maximized. Transverse displacementof the horn 133 suitably comprises transverse expansion of the horn butmay also include transverse movement (e.g., bending) of the horn.

In the illustrated embodiment, the configuration of the one-halfwavelength horn 133 is such that the nodal region is particularlydefined by a nodal plane (i.e., a plane transverse to the horn member atwhich no longitudinal displacement occurs while transverse displacementis generally maximized) is present. This plane is also sometimesreferred to as a nodal point. Accordingly, agitating members 137 (e.g.,in the illustrated embodiment, the rings) that are disposedlongitudinally further from the nodal region of the horn 133 willexperience primarily longitudinal displacement while agitating membersthat are longitudinally nearer to the nodal region will experience anincreased amount of transverse displacement and a decreased amount oflongitudinal displacement relative to the longitudinally distalagitating members.

It is understood that the horn 133 may be configured so that the nodalregion is other than centrally located longitudinally on the horn memberwithout departing from the scope of this invention. It is alsounderstood that one or more of the agitating members 137 may belongitudinally located on the horn so as to experience both longitudinaland transverse displacement relative to the horn upon ultrasonicvibration of the horn assembly 105.

Still referring to FIG. 3, the agitating members 137 are sufficientlyconstructed (e.g., in material and/or dimension such as thickness andtransverse length, which is the distance that the agitating memberextends transversely outward from the outer surface 135 of the horn 133)to facilitate dynamic motion, and in particular dynamic flexing/bendingof the agitating members in response to the ultrasonic vibration of thehorn member. In one particularly suitable embodiment, for a givenultrasonically frequency at which the waveguide assembly 101 is to beoperated in the ultrasonic chamber (otherwise referred to herein as thepredetermined frequency of the waveguide assembly) and a particularliquid to be treated within the chamber 21, the agitating members 137and horn 133 are suitably constructed and arranged to operate theagitating members in what is referred to herein as an ultrasoniccavitation mode at the predetermined frequency.

As used herein, the ultrasonic cavitation mode of the agitating membersrefers to the vibrational displacement of the agitating memberssufficient to result in cavitation (i.e., the formation, growth, andimplosive collapse of bubbles in a liquid) of the liquid being treatedat the predetermined ultrasonic frequency. For example, where the liquidflowing within the chamber comprises an aqueous solution, and moreparticularly water, and the ultrasonic frequency at which the waveguideassembly 101 is to be operated (i.e., the predetermined frequency) isabout 20 kHZ, one or more of the agitating members 137 are suitablyconstructed to provide a vibrational displacement of at least 1.75 mils(i.e., 0.00175 inches, or 0.044 mm) to establish a cavitation mode ofthe agitating members. It is understood that the waveguide assembly 101may be configured differently (e.g., in material, size, etc.) to achievea desired cavitation mode associated with the particular liquid beingtreated. For example, as the viscosity of the liquid being treatedchanges, the cavitation mode of the agitating members may need to bechanged.

In particularly suitable embodiments, the cavitation mode of theagitating members corresponds to a resonant mode of the agitatingmembers whereby vibrational displacement of the agitating members isamplified relative to the displacement of the horn. However, it isunderstood that cavitation may occur without the agitating membersoperating in their resonant mode, or even at a vibrational displacementthat is greater than the displacement of the horn, without departingfrom the scope of this invention.

In one suitable dimensional example, a ratio of the transverse length ofat least one and more suitably all of the agitating members 137 to thethickness of the agitating member is in the range of about 2:1 to about6:1. As another example, the rings 137 illustrated in FIG. 3 each extendtransversely outward from the outer surface 135 of the horn 133 a lengthof about 0.5 inches (12.7 mm) and the thickness of each ring is about0.125 inches (3.2 mm), so that the ratio of transverse length tothickness of each ring is about 4:1. It is understood, however that thethickness and/or the transverse length of the agitating members 137 maybe other than that of the rings illustrated in FIG. 3 without departingfrom the scope of this invention. Also, while the agitating members 137(rings) of the illustrated embodiment each have the same transverselength and thickness, it is understood that the agitating members mayhave different thicknesses and/or transverse lengths.

In the illustrated embodiment, the transverse length of the agitatingmember 137 also at least in part defines the size (and at least in partthe direction) of the flow path along which liquid or other flowablecomponents in the interior space 53 of the chamber 21 flows past thehorn assembly 105. For example, the horn 133 illustrated in FIG. 3 has aradius of about 0.875 inches (22.2 mm) and the transverse length of eachring 137 is, as discussed above, about 0.5 inches (12.7 mm). The radiusof the inner surface 67 of the housing sidewall 57 is approximately 1.75inches (44.5 mm) so that the transverse spacing between each ring andthe inner surface of the housing sidewall is about 0.375 inches (9.5mm). It is contemplated that the spacing between the horn outer surface135 and the inner surface 67 of the chamber sidewall 57 and/or betweenthe agitating members 137 and the inner surface of the chamber sidewallmay be greater or less than described above without departing from thescope of this invention.

In general, the horn 133 may be constructed of a metal having suitableacoustical and mechanical properties. Examples of suitable metals forconstruction of the horn 133 include, without limitation, aluminum,monel, titanium, stainless steel, and some alloy steels. It is alsocontemplated that all or part of the horn 133 may be coated with anothermetal such as silver, platinum and copper to mention a few. In oneparticularly suitable embodiment, the agitating members 137 areconstructed of the same material as the horn 133, and are more suitablyformed integrally with the horn. In other embodiments, one or more ofthe agitating members 137 may instead be formed separate from the horn133 and connected thereto to form the horn assembly 105.

While the agitating members 137 (e.g., the rings) illustrated in FIG. 3are relatively flat, i.e., relatively rectangular in cross-section, itis understood that the rings may have a cross-section that is other thanrectangular without departing from the scope of this invention. The termcross-section is used in this instance to refer to a cross-section takenalong one transverse direction (e.g., radially in the illustratedembodiment) relative to the horn outer surface 135). Additionally,although the agitating members 137 (e.g., the rings) illustrated in FIG.3 are constructed only to have a transverse component, it iscontemplated that one or more of the agitating members may have at leastone longitudinal (e.g., axial) component to take advantage of transversevibrational displacement of the horn (e.g., at and near the nodal regionof the horn illustrated in FIG. 3) during ultrasonic vibration of thewaveguide assembly 101.

For example, FIG. 5 illustrates one alternative embodiment of a hornassembly 205 having five agitating members 237 extending transverselyoutward from the outer surface 235 of the horn 233. While each of theagitating members 237 has a transverse component, e.g., in the form of aring similar to those of FIG. 3, the centermost agitating member 237also has an annular longitudinal component 241 secured to the transversecomponent. In particular, the centermost agitating member 237 isdisposed longitudinally generally at the nodal region, and moreparticularly at the nodal plane of the horn 233 in the illustratedembodiment of FIG. 5, where the transverse displacement of the horn 233is generally maximized during ultrasonic energization thereof whilelongitudinal displacement is generally minimized. The longitudinalcomponent 241 is thus capable of dynamic motion (e.g., flexing/bending)in a transverse direction in response to transverse displacement of thehorn 233 upon ultrasonic energization of the horn.

It is contemplated that the longitudinal component 241 need not extendentirely longitudinal, i.e., parallel to the outer surface of the horn233, as long as the longitudinal component has some longitudinal vectorto it. Also, while in the illustrated embodiment the agitating member237 having the longitudinal component 241 is generally T-shaped incross-section, it is understood that other configurations of such anagitating member are suitable, such as an L-shaped cross-section (withthe longitudinal component extending either up or down), a plus-shapedcross-section, or other suitable cross-section. It is also contemplatedthat one or more holes may formed in the centermost agitating member237, such as in the transverse component and/or the longitudinalcomponents 241 to allow fluid to flow freely in both the horizontal andvertical direction through this member.

As best illustrated in FIG. 3, the terminal end 103 of the waveguideassembly 101 (e.g., of the horn 133 in the illustrated embodiment) issubstantially spaced longitudinally from the outlet port 65 at theoutlet end 27 of the chamber 21 to provide what is referred to herein asa buffer zone (i.e., the portion of the interior space 53 of the chamberhousing 51 longitudinally beyond the terminal end 103 of the waveguideassembly 101) to allow a more uniform mixing of components as the liquidflows downstream of the terminal end 103 of the waveguide assembly 101to the outlet end 27 of the chamber. For example, in one suitableembodiment the buffer zone has a void volume (i.e., the volume of thatportion of the open space 53 within the chamber housing 51 within thebuffer zone) in which the ratio of this buffer zone void volume to thevoid volume of the remainder of the chamber housing interior spaceupstream of the terminal end of the waveguide assembly is suitably inthe range of about 0.01:1 to about 5.0:1, and more suitably about 1:1.

Providing the illustrated buffer zone is particularly suitable where thechamber 21 is used for mixing components together to form a liquidsolution such as in the ink solution mixing system 23 of FIG. 1. Thatis, the longitudinal spacing between the terminal end 103 of thewaveguide assembly 101 and the outlet port 65 of the chamber 21 providessufficient space for the agitated flow of the mixed liquid solution togenerally settle prior to the liquid solution exiting the chamber viathe outlet port. This is particularly useful where, as in theillustrated embodiment, one of the agitating members 137 is disposed ator adjacent the terminal end of the horn 133. While such an arrangementleads to beneficial back-mixing of the liquid as it flows past theterminal end of the horn 133, it is desirable that this agitated flowsettle out at least in part before exiting the chamber. It isunderstood, however, that the terminal end 103 of the waveguide assembly101 within the interior space 53 of the chamber 21 may be disposedlongitudinally nearer to the outlet port 65 at the outlet end 27 of thechamber, or that the buffer zone may even be substantially entirelyomitted, without departing from the scope of this invention.

The opposite, e.g., more proximal end of the horn assembly 105 issuitably spaced longitudinally from the collar 61 to define what isreferred to herein as a liquid intake zone in which initial swirling ofliquid within the interior space 53 of the chamber housing 51 occursupstream of the horn assembly 105. This intake zone is particularlyuseful where the treatment chamber 21 is used for mixing two or morecomponents together whereby initial mixing is facilitated by theswirling action in the intake zone as the components to be mixed enterthe chamber housing 51. It is understood, though, that the proximal endof the horn assembly 105 may be nearer to the collar 61 than isillustrated in FIG. 3, and may be substantially adjacent to the collarso as to generally omit the intake zone, without departing from thescope of this invention.

Still referring to FIG. 3, a baffle assembly, generally indicated at 145is disposed within the interior space 53 of the chamber 21, and inparticular generally transversely adjacent the inner surface 67 of thesidewall 57 and in generally transversely opposed relationship with thehorn assembly 105. In one suitable embodiment, the baffle assembly 145comprises one or more baffle members 147 disposed adjacent the innersurface 67 of the housing sidewall 57 and extending at least in parttransversely inward from the inner surface of the sidewall toward thehorn assembly 105. More suitably, the one or more baffle members 147extend transversely inward from the housing sidewall inner surface 67 toa position longitudinally intersticed with the agitating members 137that extend outward from the outer surface 135 of the horn member 133.The term “longitudinally intersticed” is used herein to mean that alongitudinal line drawn parallel to the longitudinal axis of the horn133 passes through both the agitating members 137 and the baffle members147. As one example, in the illustrated embodiment the baffle assembly145 comprises five, generally annular baffle members 147 (i.e.,extending continuously about the horn 133) longitudinally intersticedwith the six rings 137 of the horn assembly 105.

As a more particular example, the five annular baffle members 147illustrated in FIG. 3 are of the same thickness as the horn assemblyrings 137 (i.e., 0.125 inches (3.2 mm)) and are spaced longitudinallyfrom each other (e.g., between opposed faces of consecutive bafflemembers) equal to the longitudinal spacing between the rings (i.e.,0.875 inches (22.2 mm)). Each of the annular baffle members 147 has atransverse length (e.g., inward of the inner surface 67 of the housingsidewall 57) of about 0.5 inches (12.7 mm) so that the innermost edgesof the baffle members extend transversely inward beyond the outermostedges of the agitating members 137 (e.g., the rings). It is understood,however, that the baffle members 147 need not extend transversely inwardbeyond the outermost edges of the agitating members 137 of the hornassembly 105 to remain within the scope of this invention.

It will be appreciated that the baffle members 147 thus extend into theflow path of liquid that flows within the interior space 53 of thechamber 21 past the horn assembly 105 (e.g., within the ultrasonictreatment zone). As such, the baffle members 147 inhibit liquid againstflowing along the inner surface 67 of the chamber sidewall 57 past thehorn assembly 105, and more suitably the baffle members facilitate theflow of liquid transversely inward toward the horn assembly for flowingover the agitating members of the horn assembly to thereby facilitateultrasonic energization (i.e., agitation) of the liquid.

To inhibit gas bubbles against stagnating or otherwise building up alongthe inner surface 67 of the sidewall 57 and across the face on theunderside of each baffle member 147, e.g., as a result of agitation ofthe liquid, a series of notches 149 (broadly openings) are formed in theouter edge of each of the baffle members to facilitate the flow of gas(e.g., gas bubbles) between the outer edges of the baffle members andthe inner surface of the chamber sidewall. For example, in theillustrated embodiment four such notches are formed in the outer edge ofeach of the baffle members 147 in equally spaced relationship with eachother. It is understood that openings may be formed in the bafflemembers 147 other than at the outer edges where the baffle members abutthe housing, and remain within the scope of this invention. It is alsounderstood, that these notches 149 may instead be omitted.

It is further contemplated that the baffle members 147 need not beannular or otherwise extend continuously about the horn 133. Forexample, the baffle members 147 may extend discontinuously about thehorn 133, such as in the form of spokes, bumps, segments or otherdiscrete structural formations that extend transversely inward fromadjacent the inner surface 67 of the housing sidewall 57. The term“continuously” in reference to the baffle members 147 extendingcontinuously about the horn does not exclude a baffle members as beingtwo or more arcuate segments arranged in end-to-end abuttingrelationship, i.e., as long as no significant gap is formed between suchsegments.

For example, as best illustrated in FIG. 4, the baffle members 147 aresuitably formed separate from the tube 55 and are mounted on support rodassemblies 151 (four such rod assemblies are used in the illustratedembodiment). The support rod assemblies 151 are sized in length toextend from the outlet end 27 of the chamber (and more suitably from theclosure 63) down through each of the baffle members. The support rodassemblies 151 are secured (such as being threadably secured) to theclosure 63 to generally secure the baffle assembly 145 in place withinthe interior space 53 of the chamber 21.

More particularly, each of the annular baffle members 147 of theillustrated embodiment is of two-piece construction (each piece beingsemi-annular) for ease of assembling the baffle assembly around the hornassembly 105. For example, one set of baffle member 147 pieces ismounted on a pair of the support rod assemblies 151 and a set of thecorresponding baffle member pieces is mounted on the other pair ofsupport rod assemblies so that when all of the support rod assembliesare in place within the interior space 53 of the chamber 21 the annularshape of each baffle member is formed.

In the illustrated embodiment, each support rod assembly 151 comprises aplurality of discrete rod segments, e.g., with a rod segment extendingbetween and threadably connected to the baffle member 147 pieces. It iscontemplated, though, that each rod assembly 151 may comprise a singlerod and the baffle members 147 formed integrally with or formed separatefrom and connected to such a single rod. It is also understood that thebaffle members 147 may be of single piece construction, or constructedfrom more than two pieces, without departing from the scope of thisinvention. It is further contemplated that the baffle members 147 may besuitably supported in the interior space 53 of the chamber 21 other thanby the support rod assemblies 151 of the illustrated embodiment andremain within the scope of this invention. In other suitableembodiments, for example, the baffle members 147 may instead be formedintegrally with the tube 55 of the chamber housing 51, or formedseparate from the tube and secured to the inner surface 67 of thehousing sidewall 57.

Also, while the baffle members 147 illustrated in FIGS. 3 and 4 are eachgenerally flat, e.g., having a generally thin rectangular cross-section,it is contemplated that one or more of the baffle members may each beother than generally flat or rectangular in cross-section to furtherfacilitate the flow of gas bubbles along the interior space 53 of thechamber 21. The term cross-section is used in this instance to refer toa cross-section taken along one transverse direction (e.g., radially inthe illustrated embodiment) relative to the horn outer surface 135).

For example, FIG. 6 illustrates an alternative embodiment of a baffleassembly 345 comprised of a plurality of discrete, annular bafflemembers 347 in longitudinally spaced relationship with each other. Eachof the baffle members 347 has opposite faces 353, 355 and has anon-uniform thickness, and in particular the thickness decreases as thebaffle member extends inward away from the chamber sidewall 57. In theillustrated embodiment, the baffle members 347 are generally triangularin cross-section. More suitably, each baffle member 347 is constructedso that the lower face 353 of the baffle member extends other thansolely in the transverse direction and in particular the lower face isangled relative to the chamber sidewall 57 to extend in partlongitudinally toward the outlet end of the chamber 21. It is alsocontemplated that both the lower and the upper faces 353, 355 may beangled relative to the chamber sidewall 57 and extend in partlongitudinally toward the outlet end of the chamber 21 without departingfrom the scope of this invention.

FIGS. 7-9 illustrate another alternative embodiment of a baffle assembly545 useful in facilitating the flow of gas bubbles along the interiorspace of the chamber. In this embodiment, there are a plurality ofdiscrete baffle segments 546, each having a longitudinal outer wall 548for abutting against the chamber sidewall, and a pair of baffle members547 in the form of arcuate segments that are secured to the outer wallto extend in part circumferentially about the horn (not shown butsimilar to the horn 133 of the embodiment of FIG. 3). As best seen inFIG. 9, the longitudinal position of each of the arcuate baffle members547 gradually varies as the segment extends in a circumferentialdirection. The baffle segments 546 are each mounted on suitable supportrod assemblies 551 as described previously.

In operation according to one embodiment of the ink solution mixingsystem 23 illustrated in FIG. 1, the one or more ink components 32 (withat least one of the components being a liquid) to be mixed together aredelivered (e.g., by the pumps 31 in the illustrated embodiment) via theconduits 33 to the inlet ports 69 a, 69 b formed in the collar 61 of thetreatment chamber housing 51. As these components enter the interiorspace 53 of the chamber 21 via the inlet ports 69 a, 69 b, theorientation of the inlet ports induces a relatively swirling action toinitiate mixing of these components upstream of the horn assembly 105,such as in the fluid intake zone of the interior space of the chamber.

In accordance with one embodiment of a process for treating liquid suchas the ink solution, as the liquid solution continues to flow upwardwithin the chamber 21 the waveguide assembly 101, and more particularlythe horn assembly 105, is driven by the drive system 131 to vibrate at apredetermined ultrasonic frequency. In response to ultrasonic excitationof the horn 133, the agitating members 137 that extend outward from theouter surface 135 of the horn 133 dynamically flex/bend relative to thehorn, or displace transversely (depending on the longitudinal positionof the agitating member relative to the nodal region of the horn). Whenusing a horn assembly 205 such as that illustrated in FIG. 5 with one ofthe agitating members 237 disposed at the nodal region of the horn andhaving a longitudinal 241 component spaced transversely from the horn,the longitudinal component of the agitating member dynamicallyflexes/bends transversely relative to the horn.

Liquid solution continuously flows longitudinally along the flow pathbetween the horn assembly 105 and the inner surface 67 of the housingsidewall 57 so that the ultrasonic vibration of the agitating members137 induces mixing together of the various components being mixed. Inparticularly suitable embodiments, the dynamic motion of the agitatingmembers causes cavitation in the liquid to further facilitate agitation,and in particular mixing in the system 23 of FIG. 1, of the liquidsolution. The baffle members 147 disrupt the longitudinal flow of liquidalong the inner surface 67 of the housing sidewall 57 and repeatedlydirect the flow transversely inward to flow over the vibrating agitatingmembers 137.

As the mixed liquid solution flows longitudinally downstream past theterminal end 103 of the waveguide assembly 101 toward the buffer zone,an initial back mixing of the liquid solution also occurs as a result ofthe dynamic motion of the agitating member 137 at or adjacent theterminal end of the horn 133. Further downstream flow of the liquidsolution, e.g., within the buffer zone, results in the agitated solutionproviding a more uniform mixture of components prior to exiting thetreatment chamber 21 via the outlet port 65 for subsequentpost-processing by the post-processing system 35.

FIG. 10 illustrates one embodiment of a system, indicated generally at220, for ultrasonically treating a substance. The term substance is usedherein to refer to a liquid, solid, semi-solid or gelatinous substance.The system of FIG. 10 comprises an ultrasonic treatment device,indicated generally at 221, supported by suitable support structure,indicated generally at 222, for particular use in a batch-type processin which a solid, semi-solid or gelatinous substance is contained withina container C and ultrasonically treated (e.g., in a batch-typetreatment process) by the ultrasonic treatment device to render thesubstance more ready to flow. It is understood, however, that theultrasonic treatment device of this embodiment may be used for mixingliquids or any of the other uses set forth above in connection with theprevious embodiments.

Additionally, while the ultrasonic treatment device 221 is illustratedin FIG. 10 as being used with a generally open container C for treatinga substance therein in a batch-type process, it is understood that thisdevice may be used with the more closed, continuous flow process andtreatment chamber of the previous embodiments without departing from thescope of this invention.

The illustrated support structure 222 generally comprises a base 230, anupright 232 extending up from the base, and a support arm 224 extendingfrom the upright generally at the upper end thereof and having amounting portion 226 at a distal end of the arm for mounting theultrasonic treatment device 221 on the support structure. The supportstructure 222 also comprises a housing 228 for covering an upper extentof the ultrasonic treatment device 221 when the device is mounted on thesupport structure. The base 230 of the illustrated support structure 222generally defines a platform on which the container C is located fortreatment of the substance within the container. As an example, in theillustrated embodiment the container C is a drum, or barrel, and moreparticularly a 55-gallon drum. It is understood, however, that thecontainer C may be sized smaller or larger than a 55-gallon drum, andmay be other than drum or barrel-shaped without departing from the scopeof this invention. It is also contemplated that the base 230 need notdefine a platform on which the container C is located, such that thecontainer simply stands on the ground or other surface on which thesupport structure stands, or located on a platform (not shown) or otherstructure (not shown) that is separate from the support structure 222.

In one particularly suitable embodiment, the arm 224 is hinged orotherwise articulated to the upright 232 so that the arm and thereby theultrasonic treatment device 221 can be pivoted or otherwise movedrelative to the upright, base 230 and container C to position the deviceat a desired transverse location, depth (i.e., lowered into and raisedout of) and angle within the container. In another suitable embodiment,the upright 230 may be adjustable in length (i.e., height in theillustrated embodiment) so that the support structure 222 canaccommodate containers C of various heights. It is understood that thesupport structure 222 can have different configurations and modes ofoperation than that illustrated in FIG. 10 and described above withoutdeparting from the scope of this invention.

The ultrasonic treatment device 221 comprises an ultrasonic waveguideassembly, indicated generally at 301, operable at a predeterminedultrasonic frequency to ultrasonically energize the substance within thecontainer C. The illustrated ultrasonic waveguide assembly 301 suitablycomprises an elongate ultrasonic horn 305 having an outer surface 333and a terminal end 303, and further having a longitudinal axis that inthe embodiment of FIG. 10 defines a longitudinal axis of the entirewaveguide assembly. The illustrated elongate horn 305 is sized to have alength equal to about six one-half wavelengths of the horn. It isunderstood, however, that the length of the horn can be greater than orless than about six one-half wavelengths without departing from thescope of this invention.

The horn 305 thus has multiple nodal regions located generallylongitudinally along the horn. As used herein, a “nodal region” of thehorn 305 refers to a longitudinal region or segment of the horn alongwhich little (or no) longitudinal displacement occurs during ultrasonicvibration of the horn and transverse (e.g., radial in the illustratedembodiment) displacement of the horn is generally maximized. Transversedisplacement of the horn 305 suitably comprises transverse expansion ofthe horn but may also include transverse movement (e.g., bending) of thehorn. In the illustrated embodiment, the configuration of the ultrasonichorn 305 is such that the nodal regions are particularly defined bynodal planes (i.e., a plane transverse to the horn at which nolongitudinal displacement occurs while transverse displacement isgenerally maximized) is present. This plane is also sometimes referredto as a nodal point. For the illustrated ultrasonic horn 305, theterminal end 303 of the horn 305 defines an anti-nodal region, and moreparticularly an anti-nodal plane or point of the horn at whichlongitudinal displacement is of the horn is generally maximized duringultrasonic vibration of the horn while transverse displacement isgenerally minimized. It is understood, however, that the horn 305 may beconfigured so that a nodal region or plane is disposed at the terminalend 303 of the horn 305 without departing from the scope of thisinvention.

The illustrated waveguide assembly 301 further comprises a booster 313coaxially aligned with and connected to the ultrasonic horn 305 at anupper end of the horn. A suitable ultrasonic drive system 331 forultrasonically driving the waveguide assembly 301 comprises at least anexciter (not shown) and a power source (not shown) operatively connectedto the booster 313 (and more broadly to the waveguide assembly 301) toenergize the waveguide assembly to mechanically vibrate the horn 305 atan ultrasonic frequency. Examples of suitable ultrasonic drive systems331 include a Model 20A3000 system available from Dukane Ultrasonics ofSt. Charles, Ill., and a Model 2000CS system available from HerrmannUltrasonics of Schaumberg, Ill. The booster 313 can be operativelyconnected to the exciter by employing any conventional technique ordevice. For example, electrical power can be directed with suitableelectrical conductors to a conventional slip ring assembly 314, and theslip ring assembly can be employed to operatively direct the electricalpower to the exciter. The exciter can use the electrical power togenerate the desired ultrasonic energy, and direct the ultrasonic energyto the horn 305.

The ultrasonic treatment device 221 is suitably mounted on the distalend of the support arm to permit rotation of the ultrasonic horn 305about its longitudinal axis, and more particularly in the illustratedembodiment to permit rotation of the entire waveguide assembly 301 aboutthe longitudinal axis of the horn. As an example, in the embodiment ofFIG. 10 the waveguide assembly 301 is mounted on the support arm 224 atleast in part by a suitable bearing 354 so that the entire waveguideassembly is rotatable relative to the support structure 222 and thecontainer C about the longitudinal axis of the ultrasonic horn.

A suitable drive system, generally indicated at 342, is also mounted onthe support structure 222 (e.g., in the illustrated embodiment it ismounted on the support arm 224) is driving connection with the waveguideassembly 221 for driving rotation of the waveguide assembly, and hencethe ultrasonic horn 305. The illustrated drive system 342 comprises adrive motor 344, a first pulley 346 rotatably driven by the motor, asecond pulley 352 connected to the waveguide assembly 221 and a drivebelt 350 operatively connecting the second pulley to the first pulley.Accordingly, operation of the motor 344 to rotate the first pulleydrives rotation of the waveguide assembly 221 via the belt 352 andsecond pulley 352. It is understood that alternative drive systems forrotating the ultrasonic horn may be used without departing from thescope of this invention. In one particularly suitable embodiment, thedrive system 342 is controllable to vary the rotational speed of thewaveguide assembly 301. That is, the rotational speed of the ultrasonichorn 305 can be selectively sped up or slowed down.

With reference still to FIG. 10, the ultrasonic waveguide assembly 301further comprises at least one agitating member, generally indicated at337, supported by and more suitably mounted on the horn 305 for conjointrotation with the horn about its longitudinal axis and extending atleast in part transversely outward from the outer surface of the horn.In the illustrated embodiment, the agitating member 337 suitablycomprises a propeller having a hub 340 and a plurality of blades 338(two blades being shown on the propeller of FIG. 10) extending out fromthe hub. Each of the blades 338 is suitably twisted or canted along aportion of its length to facilitate movement of the substance by theblades upon rotation of the blades within the substance. It isunderstood that the propeller can have any number of blades and that theblades can have a configuration different that that illustrated in FIG.10 without departing from the scope of this invention.

The agitating member 337 of the illustrated embodiment is suitablymounted on the horn 305 at a nodal region or plane of the horn tominimize the exposure of the agitating member to longitudinal vibrationof the horn. More suitably, the agitating member 337 is mounted on thehorn 305 at least in part by a suitable isolating member 360 thatisolates the agitating member 337 from the transverse displacement ofthe horn during ultrasonic vibration thereof. In this manner, exposureof the agitating member 337 to both the longitudinal and transversedisplacement of the horn 305 during ultrasonic vibration is reduced. Asan example, the isolating member 360 of the illustrated embodimentcomprises a suitable resilient sleeve that surrounds the ultrasonic horngenerally at the nodal region at which the agitating member 337 islocated. The hub 340 of the agitating member fits over the resilientsleeve and clamps the sleeve between the hub and the outer surface ofthe ultrasonic horn 305.

It is understood, though, that in other embodiments the agitating member337 may be located longitudinally on the horn 305 other than at a nodalregion of the horn. In such an embodiment, suitable isolating structuremay be used to isolate the agitating member 337 from longitudinalvibration of the horn. In other such embodiments, the agitating member337 may be mounted on the horn 305 without being vibrationally isolatedtherefrom so that the blades 338 of the agitating member areultrasonically excited along with the horn, such as in the same manneras the rings described in previous embodiments, while the blades arebeing rotated.

In the illustrated embodiment of FIG. 10, the agitating member 337 issuitably located at the nodal region nearest the terminal end 303 of theultrasonic horn 305 so that the agitating member will be disposed asdeep as possible into the substance within the container C when theultrasonic treatment device 221 is positioned within the container. Itis understood, however, that the agitating member 337 may be locatedother than near the terminal end 303 of the horn 305, such assubstantially anywhere along the horn including at the terminal endthereof, without departing from the scope of this invention. It is alsocontemplated that more than one agitating member 337 may be mounted onthe horn 305 for rotation therewith.

For example, FIG. 11 illustrates an embodiment of a system 221′ in whichthe ultrasonic treatment device 221′ has four agitating members 337′mounted on the horn in longitudinal, coaxial relationship with eachother. The longitudinal spacing between agitating members 337′ may beother than as illustrated in FIG. 11 (e.g., either closer or spacedfurther apart). While the agitating members 337′ illustrated in FIG. 11are equally spaced along the horn 305, it is alternatively contemplatedthat where more than two mixing members are present the spacing betweenlongitudinally consecutive agitating members need not be uniform toremain within the scope of this invention.

While in the illustrated embodiment of FIG. 11 the agitating members 337are each propellers, it is understood that at least one of the agitatingmembers may be configured different from of one the other agitatingmembers. For example, one or more of the agitating members 337 maycomprise one of the rings used as agitating members in the priorembodiments. Also, in the illustrated embodiments of FIGS. 10 and 11 theagitating members 337 (the propellers) are mounted on the horn forconjoint rotation with the horn. However, in other embodiments it iscontemplated that the horn may be stationary while the agitating membersare mounted on the horn for rotation relative to the horn about thelongitudinal axis of the horn. In such an embodiment, the drive system342 would be operatively connected to the agitating member(s) 337instead of the entire waveguide assembly.

In operation according to one embodiment of a process for treating asubstance, the container C containing the substance to be treated isplaced on the base 230 of the support structure 222, or otherwisebeneath the ultrasonic treatment device 221, with the top of thecontainer open. The waveguide assembly 221 is lowered so that at leastthe portion of the ultrasonic horn 305 on which the agitating member 337(or members) is submerged in the substance to be treated. The ultrasonichorn 305 is ultrasonically driven (via the exciter and booster) toultrasonically excite the horn to thereby ultrasonically energize thesubstance within the container C. Concurrently, the drive system 342 isoperated to rotate the horn 305, and hence the blades 338 of theagitating member 337, to further agitate or mix the substance while itis ultrasonically energized. The waveguide assembly 301 may be movedaround within the substance, such as by changing the angle of theassembly relative to the container, by raising and lowering the assemblywithin the container and/or moving the assembly transversely within thecontainer, to facilitate a more thorough agitation through thesubstance. As one particular example, where the substance is a solid,semi-solid or gelatinous substance, such as lard or wax, ultrasonicallyenergizing the substance using the ultrasonic horn while concurrentlyrotating the agitating member within the substance substantiallyincreases the rate at which the substance is rendered more readilyflowable for further processing of the substance.

When introducing elements of the present invention or preferredembodiments thereof, the articles “a”, “an”, “the”, and “said” areintended to mean that there are one or more of the elements. The terms“comprising”, “including”, and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements.

As various changes could be made in the above constructions and methodswithout departing from the scope of the invention, it is intended thatall matter contained in the above description and shown in theaccompanying drawings shall be interpreted as illustrative and not in alimiting sense.

What is claimed is:
 1. A method of ultrasonically treating a substancedisposed within a container, the method comprising: positioning anultrasonic horn within the container with at least a portion of the hornsubmerged in the substance; ultrasonically exciting the horn to therebyultrasonically energize the substance; and rotating an agitating memberwithin the substance while the ultrasonic horn is excited to agitate thesubstance as the substance is ultrasonically energized.
 2. The methodset forth in claim 1 wherein the substance is one of a solid, semi-solidand gelatinous substance, the ultrasonic excitation step and rotatingagitating member step being performed to render the substance more readyto flow.
 3. The method set forth in claim 1 further comprisingpositioning the agitating member on the portion of the ultrasonic hornthat is submerged in the substance.
 4. The method set forth in claim 1further comprising varying the location of at least one of theultrasonic horn and the agitating member within the container whileexciting the horn and rotating the agitating member.
 5. The method setforth in claim 1 wherein positioning the ultrasonic horn within thecontainer utilizes a support structure for supporting the ultrasonichorn within the container, the horn being rotatable relative to thesupport structure about a longitudinal axis of the horn.
 6. The methodset forth in claim 3 wherein an isolating member is used to position theagitating member on the portion of the ultrasonic horn in order to atleast in part vibrationally isolate the agitating member from theultrasonic horn.
 7. The method set forth in claim 6 wherein theisolating member isolates the agitating member from at least one oflongitudinal displacement and transverse displacement of the horn.
 8. Amethod of ultrasonically treating a substance disposed within acontainer, the method comprising: positioning an ultrasonic horn withinthe container with at least a portion of the horn submerged in thesubstance; positioning an agitating member on the portion of theultrasonic horn that is submerged in the substance; ultrasonicallyexciting the horn to thereby ultrasonically energize the substance; androtating the agitating member within the substance while the ultrasonichorn is excited to agitate the substance as the substance isultrasonically energized.
 9. The method set forth in claim 8 whereinrotating the agitating member comprises rotating the ultrasonic hornduring ultrasonic excitation of the horn to thereby conjointly rotatethe agitating member.
 10. The method set forth in claim 8 furthercomprising varying the location of at least one of the ultrasonic hornand the agitating member within the container while exciting the hornand rotating the agitating member.
 11. The method set forth in claim 8wherein an isolating member is used to position the agitating member onthe portion of the ultrasonic horn in order to at least in partvibrationally isolate the agitating member from the ultrasonic horn. 12.The method set forth in claim 11 wherein the agitating member comprisesa hub surrounding an outer surface of the horn and the isolating membercomprises a sleeve constructed of a resilient material, the sleeve beingdisposed between the hub and the outer surface of the horn.
 13. Themethod set forth in claim 8 wherein the ultrasonic horn has at least onenodal region, the agitating member being disposed on the horn generallyat the nodal region.
 14. The method set forth in claim 8 wherein theagitating member comprises a propeller having a plurality of bladesarranged to extend transversely outward relative to an outer surface ofthe horn.
 15. The method set forth in claim 14 wherein each of theplurality of blades is twisted along a portion of its length.
 16. Amethod of ultrasonically treating a substance disposed within acontainer, the method comprising: positioning an ultrasonic horn withinthe container with at least a portion of the horn submerged in thesubstance; ultrasonically exciting the horn to thereby ultrasonicallyenergize the substance; and rotating a plurality of agitating memberswithin the substance while the ultrasonic horn is excited to agitate thesubstance as the substance is ultrasonically energized, the plurality ofagitating members being disposed on the horn and in longitudinal spacedrelationship with each other.
 17. The method set forth in claim 16wherein the ultrasonic horn has a length greater than one wavelength.18. The method set forth in claim 16 wherein at least one of theplurality of agitating members is rotatable about a longitudinal axis ofthe horn.
 19. The method set forth in claim 18 wherein each of theagitating members is rotatable about the longitudinal axis of the horn.20. The method set forth in claim 16 wherein the ultrasonic horn has aplurality of nodal regions, each of the agitating members being disposedon the horn at a respective one of the nodal regions.